Method for manufacturing brakeless lightweight concrete poles

ABSTRACT

A method of manufacturing concrete lightweight pole  5  and  3  respectively related to electric concrete pole to carry luminaries (street lights), power lines, communication cables and traffic signal lights. This new manufacturing method is using any size steel bars reinforcements  6  in the longitudinal direction of the pole with the horizontal stirrups  8  to adjust strength. This metallic structure secured with wire size 1/16″ diameter is combined with a lightweight high performance fiber cellular concrete mixture  4 , to form after 16 to 24 hours period curing process time, a lightweight unbreakable concrete pole with maximum bending movement.

The present application is a continuation in part of the early application filed on Jan. 21, 2003 amended on Apr. 12, 2004 and given Ser. No 10/347,468, Art unit 3632.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a new method for manufacturing a lightweight concrete pole such as electric pole to carry luminaires, overhead utility power lines, communication cables and traffic signals lights. More especially related to the creation of new lightweight unbreakable concrete pole.

2. Brief Description of Related Art

Concrete poles have been used in urban areas to support overhead transmission power cables or lighting streets, highways and traffic signals. In order to provide strength and deflection characteristics, pre cast concrete poles are reinforced with small diameter typical steels bars and pre stress concrete poles are reinforced with pre stress cables or rods.

American Concrete Institute (A.C.I) 318-83 related to rules that govern poles:

-   (iii) Concrete cover over the reinforced bars shall not be less than     1.25 inches (clause 7.7.2(a).). This clause has governed the pole     industry and engineers have forced the pre stress or pre cast     concrete manufacturing concept, which are more often used in our     streets and highways lately, replacing wood or aluminum poles.

However pre stress and pre cast concrete poles present different disadvantages and cause problems such as:

-   -   a) First, they are heavy and show instability after         installation, because its small footing cannot maintain its         plumb position.     -   b) Second, when an automobile collides with them, they break and         let fall the costly communication and power cables over cars         causing deaths.

Under all circumstances, poles used in our streets must have an improved elasticity and should be able to maintain vertical position. Electric poles should not be considered as hazardous. Some invention has provided additional composite to improve elasticity in concrete pole to a certain degree of shock or impact.

Saito et al., U.S. Pat. No. 5,542,229 on august 6, 1996, has invented a fiber reinforced-composite layer to be applied on the outer circumference of a concrete pre-stressed pole or pre cast pole in order to improve the elasticity of the pole.

Kobatake et al. U.S. Pat. No. 4,786,341 on Nov. 22, 1988, has invented a method by winding the fiber strands around the outer periphery of a concrete structural member while impregnating the fiber material with a resin to improve the elasticity of an existing concrete column.

Isley, Jr U.S. Pat. No. 5,218,810 on Jun. 15, 1993, has invented a composite reinforcement layer to be extended around the circumferential outer surface of the column to increase the resistance of concrete columns to failure under asymmetric load.

As described above, concrete poles are made with the ordinary concrete, weighting 145 lbs/ft2.

And pre-stress cables are used to increase strength and to define poles classification. Concrete poles pass classification test when pole reaches the limit of elasticity and breaks under pressure.

Cazaly, U.S. Pat. No. 4,751,804 on Jun. 21, 1988, has invented a lightweight pole, with a greater density, made with multiple polymer concrete layer or polymer impregnated concrete. One of the particular disadvantages of this method is the high ductility density aspect that makes this concrete pole breaks easier than pre stress pole under shock or pressure because of lack of elasticity and its hollow condition. The small diameter steel bars or rods will not maintain the pole from breaking in pieces as glass.

Nowadays, concrete remains one of the best raw materials for electric poles, compare to wood or metal. Wood and metal require constant maintenance and the other hand aluminum is expensive. However concrete poles present many disadvantages and described as follow:

-   -   It has been proven the difficulties to effectively meet         specification when mixing coarse aggregate, sand with proper         steel bars reinforcement in electric concrete pole. The volume         of steel would not be proportional to the volume of concrete.         (ACI 318-83, Clause 7.7.2 (a)) Industries has chosen to         manufacture the pre-stress, where in common practice, pre stress         rods are used to reinforce concrete pole and pre cast electric         concrete pole used small diameter steel bars to improve strength         and elasticity. Although the rods or metal used in common         electric concrete pole do not provide adequate resistance under         shock caused by car accidents. There have been many disastrous         incidents, including lost of lives caused by structural failure         of metal reinforcement in concrete pole. There is an urgent need         to enhance the ability of electric concrete poles to withstand         hurricane wind, shocks and breaking point.     -   Made of heavy autoclave concrete 145 lbs/ft3, concrete poles         provide poor stability because of weight disadvantage. Installed         on a small footing, poles will suffer a downward movement in         area with weak ground capacity, resulting to a sideway shift,         losing its plumb position and finally ready to fall under         hurricane wind. Dade County, in Florida State, for example, is         offering bid to re-aligned concrete pole after being installed,         because more than 35% of concrete pole installed are suffering         shifting in the past. In our theory, in common practice the         lighter a pole is, the better will present its stability.     -   Electric pre stress concrete poles break easily under pressure         or shock caused by car accident. The reinforced pre stress rods         or small diameter steel bars used cannot support the heavy         concrete pole, this is the reason engineers are being concerned         and attempts have been made to improve their elasticity which is         also a priority factor. However, concrete poles brakes under         shock and present instability after installation, therefore a         weight factor plays a great role in electric pole. This is one         of the future objectives of this invention.     -   Need special equipment to handle such as transportation and         installation. Special trailer guide is needed to control the pre         stress concrete pole from braking and the number of pole to         transport is being carefully considered. Special crane is needed         for installation and some State require deeper ground to rest         footing of concrete pole, Florida State for example, requires 7′         deep for concrete pole compare to 6′ for wood pole.     -   Need a very large area to handle and manipulate sand,         aggregates, cement and water before sending to the mixer, costly         investment pre-stress molds and infrastructures. It is an         expensive manufacturing plant.

One of the objectives of this invention is to overcome the disadvantages of conventional electric concrete pole, while presenting with same texture and appearance associated with the reinforced concrete pole.

One of the future objectives of this present invention is to provide a new lightweight concrete pole that does not breaks under shock or pressure and able to carry its own sufficient elasticity factor. There is a need to present a pole that can carry costly telecommunication, power cables, traffic lights and transformers without being a traffic hazard “unbreakable”.

Another future object of this invention is to provide a new engineering method of manufacturing electric lightweight concrete pole.

SUMMARY OF THE INVENTION

In order to solve the disadvantages inherent to the conventional engineering method, after many years of research, developing, testing and monitoring, the major breakthrough of this invention is:

-   -   Firstly, the replacement of the heavy aggregate and sand mixture         by a new revolutionary form of material, tough and lightweight         close fiber cell structure that formed the fiber reinforced         cellular concrete (FRCC). This high performance concrete resists         better to shock than conventional concrete.     -   Secondly, being a fiber cellular concrete, it offers a         particular advantage in the steel selection. Said any large         diameter of ordinary steel is chosen to reinforce the concrete         pole from butt to tip. The structure form of steel reinforcement         can be a cone, a square or a rectangular. Any size diameters         elongated steel bars placed in the longitudinal form of the pole         are reinforced with small size diameter stirrups. The large         diameter steel bar reinforcement provides an unbreakable         strength to the concrete pole. Under no circumstances, such         concrete pole can be broken by shock or pressure.

The breakthrough of this new engineering method is the use of two resistant elements such as:

Fist Element:

The fiber reinforced cellular concrete, has a lightweight of 73 lbs/ft3, said about half of the weight of the conventional concrete 145 lb/ft3. This lightweight concrete is made of:

-   -   Millions of short and long strong synthetic fiber (such as         polypropylene fiber proportionally and well distributed, replace         the aggregates).     -   Fine sand and Lightweight aggregates (such as expanded clay to         increase or adjust the density up to 7000 psi.     -   Conventional Portland cement conform to ASTMC-150 type I, type         III.     -   Thermoflex formula, Tx −600 is used to control the expansion of         the concrete.     -   Treated water (alkaline free).

The researches and tests monitoring the result of the pole attitude has now proven that this lightweight concrete is ideal to be used in this new engineering concept. The structure of the concrete used in the pole is formed by spherical fiber cells proportionally and well distributed in the mass of its mixture. The result has produced a very strong flexing strength characteristic concrete. The cracking factor is under control because of the use of fiber compared to the conventional concrete that used ordinary aggregate and sand.

Second Element:

Any size diameter steel bars are used as metallic structure to reinforce the concrete pole such as:

-   -   Four to five steel bars of ½″, ⅝″ or ¾″ of diameter are placed         longitudinally     -   Steel stirrups of ¼″ diameter are used to reinforce the metallic         structure. This metallic structure is able to provide a great         structural strength to the pole for all circumstances.     -   Wire size 1/16′ diameter secures the metallic structure.

This invention resulted in a multiples advantage:

-   -   A lighter pole because of the lightweight concrete, will present         therefore, a better stability after installation, will not lost         its vertical position. Ready to withstand 210 mph hurricane wind         force.     -   A better deflection because of the use of lightweight fiber         cellular concrete and the large steel bars diameters.     -   A pole that will never break because of the large steel bars         structure application, such application is possible only with         the use of this high performance lightweight concrete.     -   A pole with a great insulation coefficient factor R19 and not         produce flame, smoke or reduce in volume under fire.     -   A pole easy to transport and to install because of its         lightweight weight and does not require heavy equipment to         manipulate and handle.

TECHNICAL SPECIFICATION OF PYLONFLEX POLE

The concrete used in the fabrication of lightweight concrete pole has an adjustable density. Its varies from 3000 to 7000 psi and weighs respectively 73 lbs/ft3 to 90 lbs/ft3 at dry stage.

Any size of lightweight concrete pole can be designed and manufactured with this manufacturing method. The elements of reinforcements are large steel diameter combine with adjustable stirrups to increase and insure forces, resulting of a pole that can withstand maximum wind shear and cannot break under maximum pressure but will present a maximum bending movement.

The concrete used in Pylonflex pole has the faster curing process than the conventional concrete. A remarkable compressible strength is reached in 16 hours. Consequently, will have a shorter time delivery.

BRIEF DESCRIPTIONS OF THE DRAWINGS

The invention is illustrated by the followings drawings using large size diameter of steel and small size diameter stirrups combination at each section mixing with the lightweight fiber reinforced cellular concrete.

FIG. 1 shows an example of a plan configuration of an electric lightning pole, to carry luminaries.

FIG. 2 shows an example of a plan configuration of a utility pole to carry cable and transformers.

FIG. 3 shows a three dimensions way of seeing the reinforced steel bars and concrete combination.

FIG. 4 shows a three dimensions view of the tip of the lightning pole carrying the galvanized adapter pipe to support luminaires.

FIG. 5 shows a three dimensions view of the pole at ground level combined with PVC electric pipe with accessories to provide electric power to luminaries.

DETAIL DESCRIPTION OF THE INVENTION

The present invention is described in detail to provide a method of manufacturing lightweight concrete pole that is strong, unbreakable and lightweight. The breakthrough of this invention is governed by the use of a lightweight concrete 4 made of synthetic fiber (such as polypropylene fiber), fine sand, lightweight aggregates, cement, thermoflex formula and water mixing with any size diameter steel bars 6 and 8.

This high performance concrete 4, reaching 3000 psi with 73 lbs/ft3 with no autoclaves process, produces a high resistant concrete with adjustable maximum flexure strength. It is mixed with large diameter steel bars 6 and stirrups 8 in drawings FIG. 1 and FIG. 2.

The presence of proportionally well distributed fiber in the concrete mixture 4 created a reinforced cell structure that is attached strongly to steels 6 and 8.

FIG. 1 is showing the complete length h of an electric luminaire lightweight pole with a PVC pipe conduct of 11/2″ 12 for electric power wire connection from the outlet box 9. This outlet box 9 is attached to a 1″ conduct ready to plug to the power distribution box 15, galvanized 21/2″ pipe 7 placed at tip 2 to support luninaries which is also attached to the PVC pipe 12. The pole fills with lightweight concrete 4 is reinforced in three distinct way such as h1, h2 and h3 with different spacing gap stirrups 8, this concept is one of the new feature and advantage of this invention, where stirrups gap combination play a great role of strength in each vital part of the pole. h2 is the concrete pole part that requires adequate stirrups 8 reinforcement combination per example in utility line poles, said that the bending moment of the pole is reacted at this level. Concrete pole is being placed at a depth d, which is commonly used as 7′ deep d on a pole with 45 ft long h. Four regular large steel bars 6 of ⅝″ are used longitudinally. The pole 3 is made of solid lightweight concrete 4 with length b, a tip 2 and a butt 1, placed at a depth d under ground level 14. FIG. 1 shows a typical square lightweight concrete lightning street pole.

FIG. 2 is showing the complete length h of a utility power cable transportation pole, the stirrups 8 are placed at different spaces in order to provide the maximum strength at h2. h2 is therefore considered to be the critical area for bending moment and the stirrups 8 in this area are adjusted to provide adequate strength and resistance to withstand bending. One advantage of this invention is the method to create resistance of lightweight concrete pole by adjusting the stirrups 8 spacing. The pole is filled up with lightweight fiber cellular concrete 4 and reinforced longitudinally steel bars 6 which can be four ⅝″ steel bars 6 diameter or five ½″ steel bars 6 reinforced with circulars stirrups 8 to support its vertical position under forces created at the tip 2 of the pole. FIG. 2 shows a typical square lightweight concrete utility pole 5 with length b, a tip 2 and a butt 1, placed at depth d under ground level 14.

This invention results to a very stable lightweight concrete pole compare to the conventional concrete, a more resistant pole to shock because of the fiber and the steel reinforcements 6 and 8. The fiber reinforced concrete 4 weights 73 lbs/ft3 and the reinforced steel bars 6 and 8 in a 40 ft pole weights 210 lbs. The surface at tip of 40 ft pole is 25 in2, at the butt is 256 in2 for a mean area of 140.5 in2. The result of a 40 ft lightweight concrete pole is therefore 3050 lbs compare to a conventional pre stressed pole about 5,860 lbs and a wood pole weighting about 1200 lbs.

Some of the outstanding feature of this invention, necessary in the industry is the outcome of a lightweight concrete pole that does not break under shock, and tough with secure expanded fiber cell distribution. Pole showing a better stability under wind shear and hurricane wind. Pole that accepts deflection with combination of concrete cell structure and reinforced steel bars. Finishes manufactured pole at competitive cost with adequate performance, and finally light, easy to transport and install with no special handling.

FIG. 3 shows a section of the lightweight utility concrete pole 5 that includes the solid concrete 4 the reinforced longitudinal steel bars 6, and the circular stirrups 8 which provide maximum strength to pole.

FIG. 4 shows a top section of square lightweight concrete lighting pole 3 where the 21/2″ galvanized pipe 7 adapter is to receive the luminaire accessories at tip 2. Reinforced longitudinal steel bars 6 are mixed with stirrups 8 to provide maximum strength.

FIG. 5 shows a typical bottom section of the pole 3 made of lightweight concrete 4, reinforced with steel bars 6 and circular stirrups 8 providing the strength of the pole. The plastic pipe made of PVC 12 is connected to the outlet box to conduct wiring to luminaire from power distribution box 15.

BACKGROUND OF THE INVENTION

The present application is a continuation in part of the early application filed on Jan. 21, 2003 amended on Apr. 12, 2004 and given Ser. No 10/347,468, art unit 3632,

FIELD OF THE INVENTION

This invention relates to a new method for manufacturing a lightweight concrete pole such as electrics poles to carry luminaires, overhead utility power lines, communications cables, traffic signals lights. More particularly related to the creation of a new lightweight unbreakable concrete pole.

BRIEF DESCRIPTION OF RELATED ART

Concrete poles have been used in urban areas to support overhead transmission power cables or lighting streets, highways and traffic signals. In order to provide strength and deflection characteristics, pre cast concrete poles are reinforced with small diameter typical steels bars and pre stress concrete poles are reinforced with pre stress cables or rods. American Concrete Institute (A.C.I) 318-83 related to rules that govern poles:

-   (iii) Concrete cover over the reinforced bars shall not less than     1.25 inches (clause 7.7.2(a).). This clause has governed the pole     industry and engineers have forced the pre stress or pre cast     concrete manufacturing concept, which are more often used in our     streets and highways lately, replacing wood or aluminum poles.

However pre-stress and pre cast concrete poles present different disadvantages and cause problems such as:

-   -   a) First, concrete poles are heavy and show instability after         installation because its small footing cannot maintain its plumb         position.     -   b) Second, when an automobile collides with concrete poles, they         break and let fall the costly communication and power cables         over cars causing deaths. Under all circumstances poles used in         our streets must have an improved elasticity and should be able         to maintain vertical position. Electric poles should not be         considered as hazardous. Some invention has provided additional         composite to improve elasticity in concrete pole to a certain         degree of shock or impact such as:

Saito et al., U.S. Pat. No. 5,542,229 on august 6, 1996, has invented a fiber reinforced-composite layer to be applied on the outer circumference of a concrete pre-stressed pole or pre cast pole in order to improve the elasticity of the pole.

Kobatake et al. U.S. Pat. No. 4,786,341 on Nov. 22, 1988, has invented a method by winding the fiber strands around the outer periphery of a concrete structural member while impregnating the fiber material with a resin to improve the elasticity of an existing concrete column.

Isley, Jr U.S. Pat. No. 5,218,810 on Jun. 15, 1993, has invented a composite reinforcement layer to be extended around the circumferential outer surface of the column to increase the resistance of concrete columns to failure under asymmetric load.

As described above, concrete poles are made with the ordinary concrete, weighting 145 lbs/ft2. And pre-stress cables are used to increase strength and to define poles classification. Concrete poles pass classification test when pole reaches the limit of elasticity and breaks under pressure.

Cazaly, U.S. Pat. No. 4,751,804 on Jun. 21, 1988, has invented a lightweight pole, with a greater density, made with multiple polymer concrete layer or polymer impregnated concrete. One of the particular disadvantages of this method is the high ductility density aspect that makes this concrete pole breaks easier than pre stress pole under shock or pressure because of lack of elasticity and its hollow condition. The small diameter steel bars or rods will not maintain the pole from breaking in pieces as glass.

Nowadays, concrete remains one of the best raw material for electric poles, compare to wood or metal. Wood and metal require constant maintenance and the other hand aluminum is expensive. However concrete poles present many disadvantages and described as follow:

-   -   It has been proven the difficulties to effectively meet         specification when mixing coarse aggregate, sand with proper         steel bars reinforcement in electric concrete pole. The volume         of steel would not be proportional to the volume of concrete.         (ACI 318-83, Clause 7.7.2 (a)) Industries has chosen to         manufacture the pre-stress, where in common practice, pre stress         rods are used to reinforce concrete pole and pre cast electric         concrete pole used small diameter steel bars to improve strength         and elasticity. Although the rods or metal used in common         electric concrete pole do not provide adequate resistance under         shock caused by car accidents. There have been many disastrous         incidents, including lost of lives caused by structural failure         of metal reinforcement in concrete pole. There is an urgent need         to enhance the ability of electric concrete poles to withstand         hurricane wind, shocks and breaking point.     -   Made of heavy autoclave concrete 145 lbs/ft3, concrete poles         provide poor stability because of weight disadvantage. Installed         on a small footing, poles will suffer a downward movement in         area with weak ground capacity, resulting to a sideway shift,         losing its plumb position and finally ready to fall under         hurricane wind.

Dade County, in Florida State, for example, is offering bid to re-aligned concrete pole after being installed, because more than 35% of concrete pole installed are suffering shifting in the past. In our theory, in common practice the lighter a pole is, the better will present its stability. Electric pre stress concrete poles break easily under pressure or shock caused by car accident. Concrete poles do not provide enough elasticity and the reinforced pre stress rods or small diameter steel bars used cannot support the heavy concrete pole, this is the reason engineers are being concerned and attempts have been made to improve their elasticity which is also a priority factor. However, concrete poles brakes under shock and present instability after installation, therefore a weight factor plays a great role in electric pole. This is one of the future objective of this invention.

-   -   Need special equipment to handle such as transportation and         installation. Special trailer guide is needed to control the         concrete pole from braking and the number of pole to transport         is being carefully considered. Special crane is needed for         installation and some State require deeper ground to rest         footing of concrete pole, Florida State for example, requires 7′         deep for concrete pole compare to 6′ for wood pole.     -   Need a very large area to handle and manipulate sand,         aggregates, cement and water before sending to the mixer, costly         investment pre-stress molds and infrastructures. It is an         expensive manufacturing plant.

One of the objectives of this invention is to overcome the disadvantages of conventional electric concrete pole, while presenting with same texture and appearance associated with the reinforced concrete pole.

One of the future objectives of this present invention is to provide a new lightweight concrete pole that does not breaks under shock or pressure and able to carry its own sufficient elasticity factor. There is a need to present a pole that can carry costly telecommunication, power cables, traffic signal lights, luminaires and transformers without being a traffic hazard therefore “unbreakable”.

Another future object of this invention is to provide a new engineering method of manufacturing electric lightweight concrete pole.

SUMMARY OF THE INVENTION

In order to solve the disadvantages inherent to the conventional engineering method, after many years of research, developing, testing and monitoring, the major breakthrough of this invention is:

Firstly, the replacement of the heavy aggregate and sand mixture by a new revolutionary form of material, tough and lightweight close fiber cell structure that formed the fiber reinforced cellular concrete (FRCC). This high performance concrete resist better to shock than conventional concrete.

Secondly, being a fiber cellular concrete, it offers a particular advantage in the steel selection. Said any large diameter of ordinary steel is chosen to reinforce the concrete pole from butt to tip. The structure form of steel reinforcement can be a cone, a square or a rectangular. Any sizes diameters elongated steel bars placed in the longitudinal form of the pole are reinforced with small size diameter stirrups. The large diameter steel bars reinforcement provides an unbreakable strength to the concrete pole. Under no circumstances, such concrete pole can be broken by shock or pressure.

The breakthrough of this new engineering method is the use of two resistant elements such as:

Fist Element:

The fiber reinforced cellular concrete, has a lightweight of 73 lbs/ft3, said about half of the weight of the conventional concrete 145 b/ft3. This lightweight concrete is made of:

-   -   Millions of short and long strong synthetic fiber (such as         polypropylene fiber proportionally and well distributed, replace         the aggregates)     -   Fine sand and lightweight aggregates (such as expanded clay to         increase or adjust the density up to 7000 psi.     -   Conventional Portland cement conform to ASTMC-150 type I, type         III.     -   Thermoflex formula, Tx −600 is used to control the expansion of         the concrete.     -   Treated water (alkaline free).

The researches and tests monitoring the result of the pole attitude has now proven that this lightweight concrete is ideal to be used in this new engineering concept. The structure of the concrete used in the pole is formed by spherical fiber cells proportionally and well distributed in the mass of its mixture. The result has produced a very strong flexing strength characteristic concrete. The cracking factor is under control because of the use of fiber compared to the conventional concrete that used ordinary aggregate and sand.

Second Element:

Any size diameter steel bars are used to reinforce the concrete pole such as:

-   -   Four to five bars of ½″, ⅝″ or ¾″ of diameter placed         longitudinally.     -   Steel stirrups of ¼″ diameter are used to reinforce the metallic         structure. This metallic structure is able to provide a great         structural strength to the pole for all circumstances.

Wire size 1/16″ diameter secures the metallic structure.

This invention resulted in a multiples advantage:

-   -   A lighter pole because of the lightweight concrete, will present         therefore, a better stability after installation, will not lost         its vertical position. Ready to withstand 210 mph hurricane wind         force.     -   A better deflection because of the use of lightweight fiber         cellular concrete and the large steel bars diameters.     -   A pole that will never break because of the large steel bars         structure application, such application is possible for now,         only with this high performance lightweight concrete.     -   A pole with a great insulation coefficient factor R19 and not         produce flame, smoke or reduce in volume under fire.     -   A pole easy to transport and to install because of its weight         advantage, does not require heavy equipment to manipulate and         handle.

TECHNICAL SPECIFICATION OF PYLONFLEX POLE

The concrete used in the fabrication of lightweight concrete pole has an adjustable density. Its varies from 3000 to 7000 psi and weighs respectively 73 lbs/ft3 to 90 lbs/ft3 at dry stage Any size of lightweight concrete pole can be designed and manufactured with this manufacturing method. The elements of reinforcements are large steel diameter combine with adjustable stirrups to increase and insure forces, resulting of a pole that can withstand maximum wind shear and cannot break under maximum pressure but will present a maximum bending moment. The concrete used in Pylonflex pole has the faster curing process than the conventional concrete. A remarkable compressible strength is reached in 16 hours. Consequently, will assure a shorter time delivery.

BRIEF DESCRIPTIONS OF THE DRAWINGS

The invention is illustrated by the followings drawings using large size diameter of steel and small size diameter stirrups combination at each section mixing with the lightweight fiber reinforced cellular concrete.

FIG. 1 shows an example of a plan configuration of an electric lightning pole, to carry lamps.

FIG. 2 shows an example of a plan configuration of a utility pole to carry cable and transformers.

FIG. 3 shows a three dimensions way of seeing the reinforced steel bars and concrete combination.

FIG. 4 shows a three dimensions view of the tip of the lightning pole carrying the galvanized adapter pipe to support lamps.

FIG. 5 shows a three dimensions view of the pole at ground level combined with PVC electric pipe with accessories to provide electric power to lamp.

DETAIL DESCRIPTION OF THE INVENTION

The present invention is described in detail to provide a method of manufacturing lightweight concrete pole that is strong, unbreakable and lightweight. The breakthrough of this invention is governed by the use of a lightweight concrete 4 made of polypropylene fiber, fine sand, lightweight aggregates, cement, thermoflex formula and water mixing with any size diameter steel bars 6 and 8.

This high performance concrete 4, reaching 3000 psi with 73 lbs/ft3 with no autoclaves process, produces a high resistant concrete with adjustable maximum flexure strength. It is mixed with large diameter steel bars 6 and stirrups 8 in drawings FIG. 1 and FIG. 2. The presence of proportionally well distributed fiber in the concrete mixture 4 created a reinforced cell structure that is attached strongly to steels 6 and 8.

FIG. 1 is showing the complete length h of an electric lightning lightweight pole with a PVC pipe conduct of 11/2″ 12 for electric power wire connection from the outlet box 9. This outlet box 9 is attached to a 1″ conduct ready to plug to the power distribution box 15, galvanized 21/2″ pipe 7 placed at tip 2 to support lamp which is also attached to the PVC pipe 12. The pole fills with lightweight concrete 4 is reinforced in three distinct way such as h1, h2 and h3 with different spacing gap stirrups 8, this concept is one of the new feature and advantage of this invention, where stirrups gap combination play a great role of strength in each vital part of the pole. h2 is the concrete pole part that requires adequate stirrups 8 reinforcement combination per example in utility line poles, said that the bending moment of the pole is reacted at this level. Concrete pole is being placed at a depth d, which is commonly used as 7′ deep d on a pole with 45 ft long h.

Four regular large steel bars 6 of ⅝″ are used longitudinally. The pole 3 is made of solid lightweight concrete 4 with length h, a tip 2 and a butt 1, placed at a depth d under ground level 14. FIG. 1 shows a typical square lightweight concrete lightning street pole.

FIG. 2 is showing the complete length h of a utility power cable transportation pole, the stirrups 8 are placed at different spaces in order to provide the maximum strength at h2. h2 is therefore considers to be the critical area for bending moment and the stirrups 8 in this area are adjusted to provide adequate strength and resistance to withstand bending. One advantage of this invention is the method to create resistance of lightweight concrete pole by adjusting the stirrups 8 spacing. The pole is filled up with lightweight fiber cellular concrete 4 and reinforced longitudinally steel bars 6 which can be four ⅝″ steel bars 6 diameter or five ½″ steel bars 6 reinforced with circulars stirrups 8 to support its vertical position under forces created at the tip 2 of the pole. FIG. 2 shows a typical square lightweight concrete utility pole 5 with length h, a tip 2 and a butt 1, placed at depth d under ground level 14.

This invention results to a very stable lightweight concrete pole compare to the conventional concrete, a more resistant pole to shock because of the fiber and the steel reinforcements 6 and 8. The fiber reinforced concrete 4 weights 73 lbs/ft3 and the reinforced steel bars 6 and 8 in a 40 ft pole weights 210 lbs. The surface at tip of 40 ft pole is 25 in2, at the butt is 256 in2 for a mean area of 140.5 in2. The result of a 40 ft lightweight concrete pole is therefore 3050 lbs compare to a conventional pre stressed pole about 5,860 lbs and a wood pole weighting about 1200 lbs. Some of the outstanding feature of this invention, necessary in the industry is the outcome of a lightweight concrete pole that does not break under shock and tough with secure expanded fiber cell distribution. Pole showing a better stability under wind shear and hurricane wind resistant. Pole that accepts deflection with combination of concrete cell structure and reinforced steel bars. Finish manufacture pole at competitive cost with adequate performance and finally light easy to transport and install with no special handling.

FIG. 3 shows a section of the lightweight utility concrete pole 5 that includes the solid concrete 4 the reinforced longitudinal steel bars 6 and the circular stirrups 8 provide maximum strength to pole.

FIG. 4 shows a top section of square lightweight concrete lightning pole 3 where the 21/2″ galvanize pipe 7 adapter is to receive the luminaire accessories at tip 2. Reinforced longitudinal steel bars 6 are mixed with stirrups 8 to provide maximum strength.

FIG. 5 shows a typical bottom section a the pole 3 made of lightweight concrete 4, reinforced with steel bars 6 and circular stirrups 8 providing the strength of the pole. The plastic pipe made of PVC 12 is connected to the outlet box to conduct wiring to luminaire from power distribution box 15. 

1- A method of manufacturing a lightweight concrete pole, unbreakable, solid, strong and easy to handle, particularly an electric pole that can carry luminaries (streets lights), power lines communication cables and traffic signal lights. These poles can be used anywhere, therefore safe and not being an hazard to traffic compared to others. The materials that go into the manufacturing of these poles are: Lightweight fiber cellular concrete mixture 4 (FRCC) weighting 73 lbs/ft3 with adjustable density up to 7000 PSI Any size diameter ordinary steel bars 6 and 8 combination are used as structural metallic reinforcement. Said, ordinary ½″ and ⅝″ or ¾″ diameter steel bars are used to form a metallic longitudinal structure 6 and ¼″ ordinary diameter steel bars are used to form square or circular stirrups 8 are horizontal reinforcements. This metallic structure is tied and secured with wire size 1/16″ diameter. 2- A lightweight concrete pole according to claim 1 made of fiber reinforced cellular concrete 4 contains the following raw materials: thermoflex additive, Portland cement, lightweight aggregate, synthetic fiber (such as polypropylene fiber), fine sand and water. 3- A lightweight concrete pole according to claim 1 that have the ability to adjust its vertical and horizontal strength and improve its elasticity by: a) Adjusting stirrups 8 gaps in vital section h2 of the pole. b) Placing large diameter steel bars (6,8) longitudinally or vertically. 